• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    PANEL UNDERSTANDING A POLYMERIC COMPOSITE LAYER AND A REINFORCEMENT LAYER. The invention relates to a panel comprising a layer of polymeric composite and at least one reinforcement layer for reinforcing the layer of polymeric composite at least on the panel piano. The reinforcement layer 6 is made of a material that is different from that of the polymeric composite layer.
    公开号:BR112012033497B1
    申请号:R112012033497-2
    申请日:2011-06-30
    公开日:2020-11-24
    发明作者:Bruno Paul Louis Vermeulen
    申请人:Unilin, Bvba；
    IPC主号:
    专利说明:

    [0001] The present invention relates to a panel, in particular a floor panel comprising a layer of polymeric composite.
    [0002] A panel having a layer of a polymeric composite is known from WO 2008/122668. In this case the polymeric composite is WPC, which is a composite of polymeric material and a natural fiber, for example, from any source of wood. Due to the presence of polymers the dimensions of the known panels depend on the temperature more strongly than, for example, boards or wooden floor panels made mainly of wood-based material, which limits the applicability of panels including a layer of WPC.
    [0003] An object of the present invention is to provide a panel including a layer of polymeric composite which is applicable in changeable ambient conditions.
    [0004] For this purpose the panel according to the invention comprises a reinforcement layer for reinforcement of the polymeric composite layer at least on the panel piano, reinforcement layer which is made of a material that is different from that of the polymeric composite layer . The reinforcement layer can also reinforce the polymeric composite layer in a direction extending transversely to the panel piano.
    [0005] An advantage of the panel according to the invention is that deformation of the polymeric composite layer on the panel piano is minimized. In other words, the sensitivity of the panel dimensions to ambient conditions is minimized. This means that the panel can be applied in places where ambient conditions change, for example, in the case of floor panels that are connected to each other to form a floor on a floor having a floor heating system. Also, in the case of floor panels that are mutually connected to form a floor, the expansion gap between the wall and the adjacent floor panel can be minimized. In practice, the reinforcement layer is thinner than the polymeric composite layer, for example, less than 0.4 mm, but a greater thickness is possible. It is noted that the reinforcement layer can be a sheet or plate; the layer may be self-supporting and / or made of a handle.
    [0006] The polymeric composite can be a mixture of one or more polymers and non-polymeric or partially polymeric material. Examples of non-polymeric or partially polymeric materials are chalk and carpet, jute, styrene butadiene (latex), but several alternative materials are conceivable. The polymeric composite can also provide a coupling agent to improve the cohesion of the material. Alternative additives are elastomers or materials having a high load-absorbing capacity. This can also improve characteristics such as UV resistance, moisture resistance and bending resistance. The charges can be fibers, powders or the like. In general, the polymeric composite layer can be a composite of a polymeric and non-polymeric composite substance. The composite substance can be natural or unnatural fibers, particles or the like. In a practical embodiment the polymeric composite layer is a WPC layer made of plastic wood composite (WPC) and the reinforcement layer is a non-WPC reinforcement layer.
    [0007] In a preferred embodiment the reinforcement layer is incorporated into the polymeric composite layer as it creates an efficient reinforcement of the polymeric composite layer. In terms of making such a modality, the reinforcement layer can be easily integrated into a known pressing process for manufacturing a polymeric composite panel so that the reinforcement layer is embedded within the polymeric composite layer. This process is described in WO 2008/122668.
    [0008] The reinforcement layer may have an open structure. The advantage is that when pressing the melted granulate layers together while the reinforcement layer is interspersed between the layers a strong bond between the melted granulate layers in open areas of the open structure can be obtained. As a result, the reinforcement layer is fully integrated with the polymeric composite layer without significantly weakening the panel in the reinforcement layer in a direction perpendicular to the panel's piano. In this way, the resulting polymeric composite layer continues through open areas of the open structure, that is, in a direction perpendicular to the panel piano.
    [0009] The reinforcement layer may comprise longitudinal filaments and transverse filaments extending in a transverse direction with respect to the longitudinal filaments. The filaments can be oriented perpendicular to each other, but this is not necessary. The mutual distance of at least one of the longitudinal filaments and transversal filaments can vary within the reinforcement layer, which provides the opportunity to create a stronger reinforcement in predefined areas of the panel. For example, the mutual distance can vary between 1-5 filaments per cm. It is advantageous when the mutual distance is adapted to the size of the granulate that the polymeric composite layer is made; in particular, if the granulate is not fully melted it can still pass through the reinforcement layer when pressing. The filaments can be made of fiberglass, or high tenacity polyester fibers, polyester textile, cellulose, aramid, PEN, Nomex or other materials that are dimensionally insensitive to changeable ambient conditions, such as temperature changes.
    [0010] It is noted that the filaments can be attached to each other by means of fixation, for example, glue. Both filaments and the fixing means will be selected so that they are compatible with polymeric composite and preferably form a strong bond with it. In addition, binders can be added to the polymeric composite and / or reinforcement layers, such as acrylate, ethylene vinyl acetate, polyurethane, polyvinyl alcohol, polyvinyl acetate, polyvinyl chloride, styrene butadiene or similar.
    [0011] The panel may comprise at least one other reinforcement layer, which is preferably located at a distance from the reinforcement layer. A plurality of reinforcement layers is possible, too. The reinforcement layers can be located within the polymeric composite layer.
    [0012] The panel according to the invention can be a floor panel, ceiling panel, wall panel or the like.
    [0013] The invention will then be elucidated with reference to many schematic drawings showing an embodiment of the invention by way of example.
    [0014] Figure 1 is an enlarged sectional view of an embodiment of a panel according to the invention.
    [0015] Figure 2 is a series of schematic top views of different types of reinforcement layers, being applicable to the panel according to figure 1.
    [0016] Figure 3 is a series of perspective views of different types of reinforcement layers, being applicable to the panel according to figure 1.
    [0017] Figure 4 is a schematic view of an apparatus for manufacturing a panel of Figure 1.
    [0018] Figure 1 shows a cross-sectional view of an embodiment of a floor panel 1 according to the invention. The floor panel 1 includes a layer of WPC 2 made of granulated plastic wood composite (WPC) and a reinforcement layer 3. The reinforcement layer 3 is thinner than the WPC layer 2 and intends to minimize the dimensional changes of the WPC 2 layer on the panel 1 piano. In this modality, the reinforcement layer 3 is incorporated into the WPC 2 layer so that portions of the WPC 2 layer extend on both sides of the layer reinforcement 3. For reasons of stability, it is preferred that the thicknesses of these portions of the WPC 2 layer are substantially equal. It is noted that with WPC investments an alternative polymeric composite can be applied.
    [0019] In addition, the floor panel 1 according to figure 1 includes an upper laminate in the WPC layer 2. In this example, the upper laminate is a high pressure laminate construction comprising at least one printed decorative layer 4 and an impregnated protective layer 5 pressed together with cater and pressure to become a single layer due to the impregnation material which is preferably a resin as such as melamine resin. Preferably, the melamine resin is mixed with urea formaldehyde to obtain advantageous properties such as minimized crosslinking and reduced cloudiness. Coating paper 5 is preferably a high abrasion coating which preferably has aluminum oxide or other abrasion resistant hard particles embedded in the surface of the paper. It is noted that a different type of layer may be provided on the WPC layer, for example, a polymeric film having a decoration pattern, which is printed on the film. The polymeric film can be fused to the WPC layer.
    [0020] The top laminate or top layer as described above consists of one or more layers of paper, but also one or more layers of carved wood, layers of cellulosic or other suitable layers as the top layer are conceivable.
    [0021] The upper design layers and in general can be textured as embossed in registration with the design of the decorative layer printed in order to better imitate natural material, such as stone, brick, ceramic, wood, marble or similar.
    [0022] Preferably, but not necessarily, a back layer 6 is provided below the WPC layer 2 and is attached to the underside of the WPC layer 2. The back layer 6 can be used as a balance layer and it can also have properties moisture resistance. In addition, a paper layer 7 can be provided between the WPC layer and the top laminate.
    [0023] At least on two opposite sides of the floor panel 1 and preferably on all sides, coupling means 8 are formed to couple adjacent panels 1 together. Preferably, the coupling means 8 also includes a mechanical locking system for locking adjacent floor panels 1 not only in a direction perpendicular to the surface of the panels, but also in a direction parallel to the surface and perpendicular to the respective side of the floor panel. 1. However, the invention is not limited to this in any way. Although figure 1 shows a tongue and a groove as coupling means 8, all coupling systems, including the use of adhesives, are understood by the invention.
    [0024] In a preferred embodiment the reinforcement layer 3 has an open structure, as this allows the portions of the WPC layer 2 on both sides of the reinforcement layer 3 to count against each other during manufacture, hence way by creating an integral structure of the WPC layer 2 and the reinforcement layer 3. Figure 2 shows several examples of reinforcement layers 3 including an open structure. The reinforcement layers 3 as shown comprise parallel longitudinal filaments 9 and parallel transversal filaments 10 that extend in a transverse direction with respect to the longitudinal filaments 9. Filaments 9, 10 are oriented so that they envelop open areas 11. Although the longitudinal filaments 9 and the transverse filaments 10 in the modalities are perpendicularly oriented with respect to each other this is not necessary. Figure 2 also shows that reinforcement layers 3 can vary with respect to mutual distances of filaments 9, 10 in different directions, even within specific portions of reinforcement layer 3, and in filament dimensions.
    [0025] Figure 3 shows examples of different reinforcement layers 3 in perspective view. The longitudinal filaments 9 and the transverse filaments 10 can extend on top of each other and can be mutually linked at intersections of filaments 9, 10. Alternatively, the longitudinal filaments each comprise parallel filaments 9 ', 9 "which are held together to the others along the filaments 9 ', 9 "and interrupted by the transverse filaments 10 which are interspersed between the parallel filaments 9', 9" at the intersections of filaments 9 ', 9 "and the transverse filaments 10. Also, filaments 9, 10 can be laminated to a fabric 11, for example, a non-woven fabric, as shown in the lower drawing of figure 3.
    [0026] Figure 4 shows an apparatus 12 for manufacturing laminated sheets S which may include a plurality of panels 1 (see figure 1) which are cut from sheets S and are finished in a manner well known in the prior art.
    [0027] Apparatus 12 includes a first supply of granulate 13 including a mechanism 14 which is adapted to provide a first layer of granulate 15 on a supporting conveyor belt 16. Apparatus 12 further includes a second supply of granulate 17 including a mechanism 18 which is adapted to provide a second layer of granulate 19.
    [0028] Between the first supply of granulate 13 and the second supply of granulate 17, the reinforcement layer 3 is provided when unrolling it from a supply roll. The second layer of granulate 19 is provided on top of the reinforcement layer 3.
    [0029] The granulate is made of wood / plastic composite which is a material known in the prior art. It can include from about 30% by weight to about 95% by weight of at least one polymeric material and from about 5% by weight to about 80% by weight of at least one natural fiber or flour by weight of the WPC layer. Alternatively, the polymeric composite includes fibers, particles, flour or the like, which comprise one or more polymers in themselves, to which possibly one or more polymeric materials are added. The polymeric material can be one or more polymers having a polyolefin group, such as polyethylene. Other exemplary polymers include polypropylene, polyvinyl chloride, PVC copolymer and also other suitable thermoplastics. The polymer material to be processed can be in the form of powder, liquid, cuvette, pelletized and / or any other form. The polymeric material can be virgin, recycled or a mixture of both. In addition, the polymeric material can be provided with natural or non-natural additives and / or a coupling agent to improve the cohesion of the material. The polymeric material can be incorporated with a blowing agent to make a cell foam structure core.
    [0030] Natural fibers or flour have a specific moisture content, depending on the specifics and needs of the WPC board. Natural fibers can be from any source of wood, source of cellulose, other natural sources or any combination thereof. In general, any natural fiber can be used, be it from trees, plants, plant parts and the like. The specific selection of a particular type of wood and / or wood fibers can have an influence on the properties of the final panel. The fibers of an exotic hardwood type could, for example, be substantially thicker and / or longer than normal spruce wood. The folding stiffness will be greater if the WPC layer is made with longer fibers. Synthetic fibers can also be used to increase mechanical properties such as flexing and tensioning modules of the product. The natural fiber or flour can be virgin, recycled or a mixture of both. In addition, natural fibers or flour can be incorporated with a foaming agent to make a cell foam structure core.
    [0031] The mechanisms 14, 18 may include a system provided by Schilling-Knobel GmbH, as is described in WO 99/26773, which is incorporated here by way of reference, including a cutter that is resting on a measuring roller that bites the material to be spread on the conveyor belt 16. Other means are certainly conceivable.
    [0032] The lower conveyor belts 16 are longer than a second, upper conveyor belt 20, which is positioned at a distance from the first and the second granulate supply 13, 17.
    [0033] The upper conveyor belts 16, 20 run over a certain length parallel to each other and include several zones. The first zone in the direction of transport of the conveyor belts 16, 20 and a heating zone 21. In this zone, the WPC granulate is heated to a temperature so that the granulate melts to a sufficient degree to soften to a mass that can be molded into a sheet remains solid. The heating temperature depends on the polymer used in the WPC granulate and can, for example, be between 180 ° C and 250 ° C. In this exemplary embodiment, heating zone 21 is divided into a first heating zone 21A and a second heating zone 21B with pressing rollers 22 between them. These pressing rollers 22 are positioned below the conveyor part of the lower conveyor belt 16 and above the conveyor part of the upper conveyor belt 20 to perform a first pressing action on the melted granulate layers 15, 19. A second set of pressing rollers 23 consisting of two pairs of upper and lower pressing rollers performs a final pressing action on the layers 15, 19 of the melted granulate and determines the final thickness of the sheet to be formed.
    [0034] As previously described here, the reinforcement layer 3 preferably has an open structure so that the first and second layers of the melted granulate 15, 19 are pressed against each other through the open areas 11 of the reinforcement layer 13. This avoids any weak connection between layers 15, 19 due to adipation of reinforcement layer 3.
    [0035] The last zone within the conveyor belts 16, 20 and an annealing zone 24 through which the sheet layers 15, 19 are cooled and brought into the final shape. The conveyor belts 16, 20 are formed by two thermally stable belts, reinforced, for example, with glass plus Teflon®. The rear parts of the belts are in contact with heating spools in heating zones 21 A, 21B and with cooling spools in the ringing zone 24. The spools on the upper conveyor belt 20 are movable in a vertical direction, while the spools on the lower conveyor belt 16 are rigidly mounted. The mobility of the reels with the upper conveyor belt 20 and to create a gap according to the required thickness of the sheet to be formed. In principle, the heating and cooling reels do not exert pressure on the granulate layers 15, 19 and only the calibration pressing rollers 22, 23 are adapted to exert pressure on the melted granulate layers 15, 19 to determine their thickness.
    [0036] As illustrated in figure 4, a layer of paper or other absorbent material 6, 7 is provided to the bottom side of the first layer 15 and to the top side of the second layer 19 of the granulate 3 in order to be melted into it, i.e. to be attached to it through the melted plastic of the granulate. The layers of paper 6, 7 are provided by unrolling them from the supply rolls. The paper layers 6, 7 are interposed between the first layer of granulate 15 and the lower conveyor belt 16 and between the second layer of granulate 19 and the upper conveyor belt 20, respectively, so that they also assist in preventing that of the granulate layers 15, 19 sticking to the conveyor belts 16, 20. The transport speed of the paper layers 6, 7 and the reinforcement layer 3 will be adapted to that of the conveyor belts 16, 20 so that they are compatible, but it is also possible that they are not positively supplied, but are removed by the friction between the paper and the reinforcement layers and the granulate layers 15, 19 and the conveyor belts 16, 20.
    [0037] Instead of the paper layer 7, it is possible to provide a polymeric sheet, for example, polypropylene, PVC, polyester or similar, the melted granular layer of the WPC layer. The polymeric film melts and as a result of pressing, the resulting panel obtains a smooth surface on the side where the polymeric sheet is provided and melted. This is advantageous if the WPC layer has a thick surface due to the non-homogeneous mixture of the polymer and a composite substance. In addition, the polymeric layer melted on the WPC layer can also improve the stability and rigidity of the resulting panel and further improve the adhesion of another polymeric film on it which is provided at a later stage so that it does not melt completely. This additional polymeric film can be provided with a decor pattern. It is also possible to provide a melted polymeric layer or film on the back of the WPC layer, which can function as an equilibrium layer.
    [0038] At a position downstream of the upper conveyor belt 20, a cutting mechanism 25 is arranged to cut the web web into separate sheets S which are then collected for further processing in order to form the floor panel 1 accordingly. shown in figure 1.
    [0039] An alternative method of fabricating the panels according to the invention and one where a top laminate and optionally also a back layer are fixed directly to the WPC layer simultaneously with the formation of the WPC layer including the reinforcement layer 3. This it means that layers 6 and 7 (paper) are then formed by the materials for forming the top laminate and the back layer which are directly attached to the WPC layers by adhering to them. The top laminate must then be of such a structure that it can be supplied in rolls and can be attached directly to the second layer of WPC. The top laminate or the top layer may consist of layers of paper, but also one or more layers of wood carving or layers of vulcanized cellulose are designed according to the present invention as long as they withstand heat during pressing. In an additional alternative mode, the top laminate can be left out and the design can be printed directly on the WPC material. As an alternative or in addition, the raw WPC material can be embossed and / or sandblasted in a particular pattern to imitate natural materials such as wood or stone.
    [0040] From the above, it will be clear that the invention provides a panel whose dimensions are stable despite varying environmental conditions.
    [0041] The invention is not limited to the modality shown in the drawings and described below, which can be varied in different ways within the scope of the claims and the technical equivalents. For example, the reinforcement layer can be attached to an outer side of the WPC layer instead of being incorporated into it.
    权利要求:
    Claims (15)
    [0001]
    1. Panel (1), characterized by the fact that it comprises a layer of polymeric composite (2) and at least one reinforcement layer (3) for reinforcement of the polymeric composite layer (2) at least on the panel piano (1) , the reinforcement layer (3) being embedded within the polymeric composite layer (2) and made of a material that is different from that of the polymeric composite layer (2), wherein the reinforcement layer (3) is more thinner than the polymeric composite layer (2).
    [0002]
    2. Panel (1) according to claim 1, characterized by the fact that the polymeric composite layer (2) and a WPC layer (2) made of plastic wood composite (WPC) and the reinforcement layer ( 3) and a non-WPC reinforcement layer (3).
    [0003]
    3. Panel (1) according to claim 1, characterized by the fact that the polymeric composite is a mixture of one or more polymers and non-polymeric materials, in which the non-polymeric material and chalk.
    [0004]
    4. Panel (1) according to any one of the preceding claims, characterized in that the reinforcement layer (3) has an open structure.
    [0005]
    5. Panel (1) according to claim 4, characterized by the fact that the polymeric composite layer (2) is continued through open areas (11) of the open structure.
    [0006]
    6. Panel (1) according to any one of the preceding claims, characterized in that the reinforcement layer (3) comprises a fiber web.
    [0007]
    Panel (1) according to any one of the preceding claims, characterized in that the reinforcement layer (3) comprises longitudinal filaments (9, 9 ', 9 ") and transversal filaments (10) extending in the direction transversal to the longitudinal filaments (9, 9 ', 9 ").
    [0008]
    8. Panel (1) according to claim 7, characterized in that the mutual distance of the longitudinal filaments (9, 9 ', 9 ") and / or the transverse filaments (10) varies within the reinforcement layer.
    [0009]
    9. Panel (1) according to claim 7 or 8, characterized in that said filaments are made of fiberglass, and are fixed to each other by means of fixation and in which binders are added to reinforcement layer (3).
    [0010]
    10. Panel (1) according to any one of the preceding claims, characterized in that the reinforcement layer (3) is a sheet or plate.
    [0011]
    11. Panel (1) according to any one of the preceding claims, characterized in that the reinforcement layer (3) is made of a piece.
    [0012]
    12. Panel (1) according to any one of the preceding claims, characterized in that the panel (1) comprises at least one other reinforcement layer, preferably located at a distance from the reinforcement layer (3) .
    [0013]
    13. Panel (1) according to any one of the preceding claims, characterized by the fact that the polymeric composite layer contains at least 30% polymer.
    [0014]
    14. Panel (1) according to any one of the preceding claims, characterized in that the panel (1) is a floor panel and at least on two opposite sides of said floor panel coupling means are formed to couple adjacent floor panels together.
    [0015]
    15. Panel (1) according to any one of the preceding claims, characterized by the fact that a polymeric film is provided in the polymeric composite layer, wherein said polymeric film has a decoration pattern that is printed on the film .
    类似技术:
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    法律状态:
    2017-06-20| B25A| Requested transfer of rights approved|Owner name: UNILIN, BVBA (BE) |
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-10-08| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-07-07| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-11-24| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 30/06/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    EP10167985.0|2010-06-30|
    EP20100167985|EP2402155A1|2010-06-30|2010-06-30|A panel comprising a polymeric composite layer and a reinforcement layer|
    PCT/EP2011/060991|WO2012001091A1|2010-06-30|2011-06-30|A panel comprising a polymeric composite layer and a reinforcement layer|
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